CROSS-REFERENCE TO RELATED APPLICATION
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to systems and methods for monitoring an excavation
vacuum apparatus and, in particular, systems and methods that sense build-up of spoil
material to prevent pluggage of the system.
BACKGROUND
[0003] At least some known excavation vacuum systems involve directing high pressure water
at an excavation site while removing cut earthen material and water by a vacuum system
to perform an excavation operation. The spoil material is removed by entraining the
spoil material in an airstream generated by the vacuum system. In some known excavation
systems, the spoils are subsequently separated from the airstream by a spoil separation
system. Spoil separation systems may utilize a plurality of processing units in order
to remove water from the spent soils. After processing, the separated spoils are discharged
from the separation system for reuse at the excavation site or for other disposal.
[0004] In some known cases, during the course of an excavation operation, spoils may begin
to build-up in one or more of the components of the separation system. Build-up of
spoils may decrease efficiency and adversely affect one or more processing units of
the separation system. Further, spoil build-up in one unit affects adjacent processing
units in a cascading effect. Specifically, if the spoil buildup is not detected and
cleared in a timely manner, the spoil build-up may rapidly increase. The build-up
may completely block the separation system causing damage to one or more components
thereof. Additionally, clearing a blocked separation system and/or repairing processing
units of the separation system may be a time consuming process that may delay project
deadlines and increase the down time of the excavation apparatus. Further, clearing
a plugged separation system may require that the excavation apparatus be transported
to another location in order to avoid issues at the excavation site.
[0005] To prevent spoils pluggage in a separation system, an operator may need to diligently
monitor the components of the separation system in order to ensure that the separation
system is functioning properly and that spoils are not building up in the various
processing units of the system. Monitoring spoil buildup may strain the operator because
the operator's attention is drawn to multiple aspects of the excavation apparatus
and the separation system during an excavation operation.
[0006] A need exists for methods and systems for identifying a spoils build-up condition
on an excavation vacuum apparatus and for executing one or more clearing operations
that may be used to mitigate further progression of the build-up. Additionally, in
the event that the separation system becomes plugged, a need exists for automated
shut-down operations to prevent further damage to the components of the separation
system.
[0007] This section is intended to introduce the reader to various aspects of art that may
be related to various aspects of the disclosure, which are described and/or claimed
below. This discussion is believed to be helpful in providing the reader with background
information to facilitate a better understanding of the various aspects of the present
disclosure. Accordingly, it should be understood that these statements are to be read
in this light, and not as admissions of prior art.
SUMMARY
[0008] One aspect of the present disclosure is directed to a mobile excavation vacuum apparatus.
The apparatus includes a vacuum system for removing spoil material from an excavation
site by entraining the spoil material in an airstream. The system includes a disentrainment
system for removing spoil material from the airstream. A pluggage monitoring system
includes one or more sensors for measuring the weight of at least a portion of the
disentrainment system. A chassis supports the mobile excavation apparatus and one
or more wheels mounted to the chassis.
[0009] Another aspect of the present disclosure is directed to a disentrainment system for
removing spoil material from an airstream. The disentrainment system includes one
or more vessels and/or cyclones for continuously removing spoil material from the
airstream. The disentrainment system includes a sensor system for weighing at least
a portion of the disentrainment system. The disentrainment system includes a controller
for receiving a signal from the sensor system to determine a measured weight of at
least a portion of the disentrainment system. The controller is configured to compare
the measured weight to a threshold weight. The controller is further configured to
activate a spoil material clearing operation if the measured weight exceeds the threshold
weight.
[0010] Yet another aspect of the present disclosure is directed to a method for monitoring
build-up of spoil material in a disentrainment system of a mobile excavation vacuum
apparatus. Spoil material is vacuumed from an excavation site by entraining the spoil
material in an airstream. The airstream having spoil material entrained therein is
introduced into a disentrainment system to remove the spoil material from the airstream.
The weight of at least a portion of the disentrainment system is monitored to determine
if spoil material is building up in the disentrainment system.
[0011] A further aspect of the present disclosure is directed to a mobile excavation vacuum
apparatus. The apparatus includes a vacuum system for removing spoil material from
an excavation site by entraining the spoil material in an airstream. The apparatus
includes a disentrainment system for removing spoil material from the airstream. The
disentrainment system includes an outlet through which spoil material is discharged
from the disentrainment system. The disentrainment system has a vacuum tube in fluid
communication with a vacuum pump. The vacuum tube has a flexible segment. The apparatus
includes a mounting frame from which at least a portion of the disentrainment system
is suspended. The mounting frame has first and second rotational joints. The flexible
segment of the vacuum tube has an axis that passes through the second joint.
[0012] Various refinements exist of the features noted in relation to the above-mentioned
aspects of the present disclosure. Further features may also be incorporated in the
above-mentioned aspects of the present disclosure as well. These refinements and additional
features may exist individually or in any combination. For instance, various features
discussed below in relation to any of the illustrated embodiments of the present disclosure
may be incorporated into any of the above-described aspects of the present disclosure,
alone or in any combination.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013]
FIG. 1 is a perspective view of an excavation vacuum apparatus;
FIG. 2 is a side view of the excavation vacuum apparatus;
FIG. 3 is a schematic of water and air flow in the excavation vacuum apparatus;
FIG. 4 is a partial side view of the excavation vacuum apparatus showing the disentrainment
system;
FIG. 5 is a block diagram of a system for reducing or preventing pluggage of spoil
material in the excavation vacuum apparatus;
FIG. 6 is a block diagram of a clearing module of the pluggage monitoring system of
the excavation vacuum apparatus;
FIG. 7 is a front view of a separation vessel, shown as a deceleration vessel, and
an airlock;
FIG. 8 is a top view of the deceleration vessel and a deflection plate;
FIG. 9 is a side view of the deceleration vessel and airlock;
FIG. 10 is a perspective view of a cyclonic separation system of the excavation vacuum
apparatus;
FIG. 11 is a perspective view of a dewatering system of the excavation vacuum apparatus;
FIG. 12 is a front view of a remote console supporting a user interface of the excavation
vacuum apparatus; and
FIG. 13 is a photo of a joint at which a disentrainment system of the excavation vacuum
apparatus connects to a mounting frame.
[0014] Corresponding reference characters indicate corresponding parts throughout the drawings.
DETAILED DESCRIPTION
[0015] Provisions of the present disclosure relate to systems for reducing or preventing
pluggage of spoil material in an excavation vacuum apparatus. The pluggage prevention
system of the excavation vacuum apparatus may trigger one or more mitigation operations
(e.g., addition of water through spray nozzles) to loosen the build-up of spoil material
and/or to at least partially shut down the excavation vacuum apparatus to prevent
more material being fed to the system.
[0016] An example excavation vacuum apparatus 3 (or more simply "excavation apparatus 3"
or even "apparatus 3") for excavating earthen material which may include a system
for reducing or preventing build-up or pluggage of spoil material in accordance with
embodiments of the present disclosure is shown in FIGS. 1 and 2. As described in further
detail herein, the excavation apparatus 3 is used to excavate a site by use of a jet
of high pressure water expelled through a wand. The cut earthen material and water
are removed by a vacuum system and are processed onboard the apparatus by separating
the cut earthen material from the water. Processed water may suitably be stored onboard
(e.g., in one or more water tanks 30 (FIG. 4)) and used for additional excavation
or disposed. Recovered earthen material is discharged from the apparatus 3 and may
be used to backfill the excavation site or disposed.
[0017] It should be understood that while the excavation apparatus 3 may be described and
shown herein as using high pressurized water for excavation, in other embodiments,
the excavation apparatus may use high pressure air to excavate the site. Further,
while the illustrated apparatus may process disentrained (i.e., separated) spoiled
material such as by dewatering the spoiled material, in other embodiments the spoil
material is not processed and is off-loaded without processing or is collected onboard.
[0018] The excavation apparatus 3 includes a front 10, rear 18, and a longitudinal axis
A (FIG. 1) that extends through the front 10 and rear 18 of the apparatus 3. The apparatus
3 includes a lateral axis B that is perpendicular to the longitudinal axis A. An example
excavation system is disclosed in
U.S. Patent Publication No. 2019/0017243, entitled "Hydro Excavation Vacuum Apparatus and Fluid Storage and Supply Systems
Thereof", which is incorporated herein by reference for all relevant and consistent
purposes.
[0019] The excavation apparatus 3 may include a chassis 14 (FIG. 2) which supports the various
components (e.g., vacuum system, disentrainment system and/or dewatering system) with
wheels 16 connected to the chassis 14 to transport the excavation apparatus 3. The
excavation apparatus 3 may be self-propelled (e.g., with a dedicated motor that propels
the apparatus) or may be adapted to be towed by a separate vehicle (e.g., may include
a tongue and/or hitch coupler to connect to the separate vehicle).
[0020] The excavation apparatus 3 includes a dedicated engine 26 that powers the various
components such as the excavation pump, vacuum pump, vibratory screens, conveyors
and the like. In other embodiments, the engine 26 is eliminated and the apparatus
is powered by a motor that propels the apparatus or the excavation apparatus is powered
by other methods.
[0021] The excavation apparatus 3 includes a wand 4 (FIG. 3) for directing pressurized water
W toward earthen material to cut the earthen material (or for supplying a high pressure
airstream as with air excavators). The wand 4 is connected to an excavation fluid
pump 6 that supplies water to the wand 4.
[0022] The excavation apparatus 3 includes a vacuum system 7 (FIG. 2) for removing spoil
material from the excavation site. Spoil material or simply "spoils" may include,
without limitation, rocks, cut earthen material (e.g., small particulate such as sand
to larger pieces of earth that are cut loose by the jet of high pressure water), slurry,
vegetation (e.g., sticks, roots or grass) and water used for excavation. The spoil
material may have a consistency similar to water, a slurry, or even solid earth or
rocks. The terms used herein for materials that may be processed by the excavation
apparatus 3 such as, for example, "spoils," "spoil material," "cut earthen material"
and "water", should not be considered in a limiting sense unless stated otherwise.
[0023] The vacuum system 7 includes a boom 9 that is capable of rotating toward the excavation
site to remove material from the excavation site. The boom 9 may include a flexible
portion 5 (FIG. 3) that extends downward to the ground to vacuum spoil material from
the excavation site. The flexible portion 5 may be manipulated by a user to direct
the vacuum suction toward the excavation site.
[0024] The vacuum system 7 acts to entrain the cut earth and the water used to excavate
the site in a stream of air. A blower or vacuum pump 24 (Fig. 3) pulls a vacuum through
the boom 9 to entrain the material in the airstream. Air is discharged from the blower
24 after spoil material is removed from the airstream.
[0025] The airstream having water and cut earth entrained therein is pulled through the
boom 9 and through a series of conduits (e.g., conduit 47 shown in FIG. 9) and is
pulled into a disentrainment system 46. In the embodiment illustrated in FIG. 3, the
disentrainment system 46 includes a separation vessel 21, airlock 55 for discharging
material from the separation vessel 21, one or more cyclones 11, one or more conveyors
80 for removing material from the cyclones 11 and a cyclone discharge pump 20. The
disentrainment system 46 is an example system and, in accordance with other embodiments
of the present disclosure, may include more or less processing units that are arranged
in different configurations. Generally, any disentrainment system that removes earthen
material from an airstream may be used unless stated otherwise. A pluggage prevention
system 60 (FIG. 5) (which may also be referred to as a pluggage monitoring system)
reduces build-up or plugging of spoil material in the disentrainment system 46 as
further described below.
[0026] The disentrainment system 46 includes a separation vessel 21 and cyclones 11 for
removing spoil material from the airstream. The separation vessel 21 is a first stage
separation in which the majority of spoil material is removed from the airstream with
carryover material in the airstream being removed by the cyclones 11 in a second stage
(i.e., the separation vessel 21 is the primary separation vessel with the downstream
cyclones 11 being secondary separation vessels).
[0027] The separation vessel 21 (FIG. 7) removes at least a portion of cut earthen material
and water from the airstream. Air exits one or more separation vessel air outlets
49 and is introduced into cyclones 11 (FIG. 2) to remove additional spoil material
(e.g., water, small solids such as sand, low density particles such as sticks and
grass, and the like) not separated in the separation vessel 21. Spoil material discharged
from the bottom of the cyclones 11 is conveyed to a cyclone discharge pump 20 (FIG.
10) (e.g., peristaltic pump described in further detail below) and is introduced to
the dewatering system 95 described below, or, alternatively, is gravity fed to the
dewatering system 95. The air removed from the cyclones 11 is drawn through a vacuum
tube 22 (FIG. 3) to be introduced into one or more filter elements 28 before entering
the vacuum pump 24. The vacuum pump 24 may be disposed in or near the engine compartment
26 (FIG. 2). Air is removed from the apparatus through a vacuum exhaust 29.
[0028] The vacuum pump 24 generates vacuum in the system to pull water and cut earthen material
into the excavation apparatus for processing. In some embodiments, the vacuum pump
24 is a positive displacement pump. Such positive displacement pumps may include dual-lobe
or tri-lobe impellers (e.g., a screw rotor) that draw air into a vacuum side of the
pump and forces air out the pressure side.
[0029] Spoil material containing water and cut earth is introduced into the separation vessel
21 through inlet conduit 47 (FIG. 9). At least a portion of spoil material falls from
the airstream to a spoil material outlet 33 (FIG. 8) and into an airlock 55. Air removed
through air outlets 49 is processed in cyclones 11 (FIG. 2) to remove at least a portion
of carryover spoil material.
[0030] The cyclones 11 may be part of a cyclonic separation system 67 (FIG. 4). The cyclones
11 receive airflow from the separation vessel 21. Cyclonic action in the cyclones
11 causes entrained spoil material to fall to the bottom of the cyclones 11 and into
conveyors 80A, 80B (FIG. 10). Air pulled through the cyclones 11 is discharged through
cyclone discharge manifolds 78A, 78B and is directed to one or more filter elements
28 (FIG. 3) before entering the vacuum pump 24 (FIG. 3).
[0031] The conveyors 80A, 80B are sealed to reduce or prevent air from entering the vacuum
system through the conveyors 80A, 80B (e.g., having gaskets or bearings or the like
that seal the conveyor from the ambient atmosphere). The conveyors 80A, 80B may be
screw conveyors (e.g., an auger) having a rotating screw therein. The screw conveyor
may be a centerless screw conveyor. In other embodiments, the screw conveyor may include
a center shaft. In yet other embodiments, the one or more conveyors 80 may be slat
conveyors, belt conveyors or rotary vane conveyors. In other embodiments, the conveyors
80A, 80B are eliminated (e.g., replaced with one or more airlocks). The conveyors
80 are powered by motors which may be quick-attach motors to facilitate clean-out
of the conveyors 80. The cyclonic separation system 67 may generally include any number
of cyclones 11 and conveyors 80. The conveyors 80 convey material to the cyclone discharge
pump 20. The cyclone discharge pump 20 may be sealed and configured to prevent air
entry during discharge of spoil material.
[0032] The excavation apparatus 3 includes a spray nozzle system 100 (FIG. 3) that may be
used to clear a spoil build-up in one or more of the components of the disentrainment
system 46. The spray nozzle system 100 directs pressurized water towards one or more
of the components of the disentrainment system 46 in order to break apart a spoil
build-up.
[0033] The spray nozzle system 100 may include a spray pump 102 that is used to provide
pressurized water to the spray nozzles assemblies 104, 106. In some example embodiments,
the spay pump 102 may be the excavation fluid pump 6 that supplies water to the wand
4. In other embodiments, the spray nozzles assemblies 104, 106 may be supplied with
pressurized water through a separate spray pump dedicated to provide pressurized water
to one or more of the spray nozzle assemblies 104, 106.
[0034] In this illustrated embodiment, the spray nozzle system 100 includes a first spray
nozzle assembly 104 and a second spray nozzle assembly 106. The first spray nozzle
assembly 104 is arranged to add spray water to airlock 55 and/or the separation vessel
21, such that the first spray nozzle assembly 104 may be use to clear a spoil build-up
within at least one of the separation vessel 21 and/or the airlock 55. The second
spray nozzle assembly 106 may provide spray water to the cyclones 11 and/or the conveyors
80. As such, the second spray nozzle assembly 106 may be use to clear or break apart
a spoils build-up within at least one or more of the cyclones 11 and/or the conveyors
80. In other example embodiments, the excavation apparatus 3 includes additional or
different spray nozzle assemblies that may be used to clear a spoil build-up in one
or more components of the disentrainment system 46.
[0035] The spray nozzle assemblies 104, 106 may be stationary such that the pressurize water
expelled from a the spray nozzle assembly 104, 106 is directed towards a relatively
fixed position within the disentrainment system 46. In alternative example embodiments,
an operator may adjust the direction of the pressurized water by adjusting the position
of the spray nozzle assemblies 104, 106. For example, an operator may selectively
adjust the position of the spray nozzle assemblies to redirect the direction of the
pressurized water. In other example embodiments, the position of the spray nozzle
assemblies 104 may be adjusted via a motorized system, such as a robotic system.
[0036] One or more of the components of the disentrainment system 46 are coupled to a disentrainment
system frame 110 (FIG. 4). The disentrainment system frame 110 supports the separation
vessel 21, airlock 55, conveyors 80, cyclones 11, and pump 20. The components supported
by the disentrainment system frame 110 may be collectively referred to herein as the
weighed separation system 112 (shown in FIG. 3). In other example embodiments, different
or additional components of the excavation apparatus 3 (e.g., the disentrainment system
46) may be mounted to the disentrainment system frame 110. In some embodiments, the
entire disentrainment system 46 is weighed (i.e., is the weighed system 112) and,
in other embodiments, only a portion of the disentrainment system 46 is weighed (i.e.,
is part of the weighed system 112). The weighed system 112 may be coupled to the disentrainment
system frame 110 by any means, for example and without limitation, bolts, rivets,
and/or welded connections.
[0037] In this illustrated embodiment, the disentrainment system frame 110 is coupled to
a mounting frame 114 (FIG. 4), such that the mounting frame 114 supports the disentrainment
system frame 110 and likewise any component coupled to the disentrainment system frame
110. The mounting frame 114 is coupled to the chassis 14 of the excavation apparatus
3.
[0038] The disentrainment system frame 110 is connected to the mounting frame 114 at one
or more joints. In this illustrated embodiment, the disentrainment system frame 110
is supported by the mounting frame 114 at two joints, a first joint 120 and a second
joint 122. The second joint 122 is a rotational joint which allows the disentrainment
system frame 110 to rotate relative to the mounting frame 114 about an axis parallel
to the chassis 14 and substantially parallel to axis B (i.e., the disentrainment system
46 is suspended from the second joint 122 such that the weight of the disentrainment
system 46 causes the first joint 120 to be in tension). The first joint 120 is used
to support a sensor 121 mounted between the mounting frame 114 and the disentrainment
system frame 110. In this dual support configuration, changes in weight of the disentrainment
system 46 causes a parameter at the first joint 120 measured by the sensor 121 to
be altered (i.e., changes in forces and/or moments experienced by the sensor 121 at
the first joint 120) .
[0039] The disentrainment system frame 110 is supported by the mounting frame 114 such that
the center of weight of the disentrainment system 46 is located a distance away from
the second joint 122. As such, the weight of the weighed system 112 and/or the weight
of the separation system frame may generate a moment about the second joint 122. Additionally
and/or alternatively, changes in the weight of the weighed disentrainment system 112
may increase or decrease the moments about the second joint 122. More specifically,
spoil build-up within one or more components of the weighed disentrainment system
112 may increase the moment about the second joint 122.
[0040] The mounting frame 114 includes a first sensor mount 124 and a mounting frame lower
mount 126 that connect the disentrainment system frame 110 to the mounting frame.
The mounting frame lower mount 126 may include a hinge pin 140 (FIG. 13) that extends
through two brackets (one bracket 128 being shown in FIGS. 4 and 13). The disentrainment
system 46 includes a disentrainment system lower mount 136. In the illustrated embodiment,
the disentrainment system lower mount 136 includes two lobes (first lobe 138 shown
in FIG. 13) that extend from the airlock 55. The disentrainment system lower mount
136 is free to move (i.e., pivot) about the hinge pin 140 such that the weighed system
112 of the disentrainment system 46 are suspended from the mounting frame 114 at the
second joint 122.
[0041] The disentrainment system frame 110 includes a second sensor mount 132. More specifically,
at the first joint 120, the sensor 121 is mounted between the first sensor mount 124
coupled to the mounting frame 114 and the second sensor mount 132 coupled to the disentrainment
system frame 110. In the illustrated embodiment, the sensor 121 is a load cell sensor.
The load cell sensor 121 may be used to detect at least one or more of force in tension
and/or compression and/or a bending moment at the first joint 120.
[0042] In should be understood that, if not mitigated, the vacuum pressure within the vacuum
tube 22 may induce additional forces and/or moments on the disentrainment system 46
thereby affecting the force/torques experienced at least one of the first joint 120
and/or the second joint 122. In some embodiments, the vacuum tube 22 is arranged such
that a vacuum force induces minimal and/or reduced forces on the first joint 120.
In the illustrated embodiment, the vacuum tube 22 includes a flexible segment 152.
The flexible segment 152 is arranged such that the vacuum force is directed along
an axis A
22 that passes near or through the second joint 122, such that the vacuum force does
not generate a significant moment about the second joint 122.
[0043] The various hoses and connections (e.g., vacuum tube 22 from cyclones 11 to the vacuum
pump 2, connection of boom 9 to the inlet of the separation vessel 21 and the like)
may have one or more isolating or "damping" sections (e.g., flexible and/or rubber
joints). Such damping sections reduce the forces transmitted through such hoses and
connections being further transmitted to the weighed system 112. This improves the
accuracy of the sensor 121. Additionally, weight changes created by various other
connections between the weighed system 112 and other components of the apparatus 3
(e.g., water hoses, hydraulic hoses, electrical wires) can be accounted for during
calibration or are negligible.
[0044] The excavation apparatus includes a sensor system 130 (FIG. 5) that detects a spoil
build-up within one or more components of the disentrainment system 46. The sensor
system 130 and controller 150 described below may be part of a pluggage prevention
system 60 (FIG. 5) to prevent the disentrainment system 46 from becoming plugged or
occluded with earthen material.
[0045] The pluggage prevention system 60 may generally include any sensor system 130 that
is capable of detecting a spoil build-up unless stated otherwise. In the illustrated
embodiment, the sensor system 130 includes the load cell 121 used to detect the weight
of one or more components of the disentrainment system 46 and/or the weight of the
spoil material contained within the components of the disentrainment system 46. In
other example embodiments, the sensor system 130 includes one or more additional sensors.
For example, in some alternative embodiments, the sensor system 130 includes one or
more of a flow meter. The one or more flow meters may be used to detect the mass flow
from entering into the disentrainment system and to detect the mass flow exiting the
system. Additionally or alternatively, the sensor system 130 may include one or more
of an ultrasound sensor that may be used to detect spoil build-up within the disentrainment
system. In other embodiments, the sensor system 130 may include additional or alternative
sensors that enable the disentrainment system to function as described herein.
[0046] The one or more sensors of the sensor system 130 produce a signal that is transmitted
to a disentrainment controller 150 (FIG. 5). The disentrainment controller 150 may
control additional aspects of the excavation apparatus 3 (e.g., controlling the flow
of liquids in the fluid storage and supply system 25) or a dedicated controller may
be used. The disentrainment controller 150 monitors the disentrainment system 46 for
spoil build-up and/or pluggage within one or more components of the disentrainment
system 46. The disentrainment controller 150 is communicatively coupled to the sensor
system 130.
[0047] In the illustrated excavation apparatus 3, the load cell sensor 121 transmits a signal
to the controller 150 indicating the amount of force and/or torque experienced by
the load cell sensor 121 at the first joint 120. As described above, the load cell
sensor 121 measures forces and/or torques associated with the combined weight of spoil
material contained within the weighed system 112 of the disentrainment system 46.
In this illustrated embodiment, the load cell sensor 121 measures a force and/or a
torque associated with the total combined weight of the weighed system 112 (e.g.,
cyclones 11, the separation vessel 21, the airlock 55, the conveyor 80, the peristaltic
pump 20) and any spoil material contained in any of these units.
[0048] The controller 150 is communicatively coupled to the spray pump 102 and/or valving
between the pump 102 and the nozzle assemblies 104, 106 such that the controller 150
may selectively power the spray pump 102 to selectively provide pressurized water
to the first spray nozzle assembly 104 and/or the second spray nozzle assembly 106.
The controller 150 controls the spray pump 102 based on instructions stored in a memory
device (not shown), inputs received from the load cell sensor 121, inputs from a user
via a user interface 160 (described below), and/or input received from any other suitable
data source.
[0049] Disentrainment controller 150, the various logical blocks, modules, and circuits
described herein may be implemented or performed with a general purpose computer,
a digital signal processor (DSP), an application specific integrated circuit (ASIC),
a field programmable gate array (FPGA), or other programmable logic device, discrete
gate or transistor logic, discrete hardware components, or any combination thereof
designed to perform the functions described herein. Example general purpose processors
include, but are not limited to, microprocessors, conventional processors, controllers,
microcontrollers, state machines, or a combination of computing devices.
[0050] Disentrainment controller 150 includes a processor, e.g., a central processing unit
(CPU) of a computer for executing instructions. Instructions may be stored in a memory
area, for example. Processor may include one or more processing units, e.g., in a
multi-core configuration, for executing instructions. The instructions may be executed
within a variety of different operating systems on the controller, such as UNIX, LINUX,
Microsoft Windows®, etc. It should also be appreciated that upon initiation of a computer-based
method, various instructions may be executed during initialization. Some operations
may be required in order to perform one or more processes described herein, while
other operations may be more general and/or specific to a particular programming language
e.g., and without limitation, C, C#, C++, Java, or other suitable programming languages,
etc.
[0051] Processor may also be operatively coupled to a storage device. Storage device is
any computer-operated hardware suitable for storing and/or retrieving data. In some
embodiments, storage device is integrated in controller. In other embodiments, storage
device is external to controller and is similar to database. For example, controller
may include one or more hard disk drives as storage device. In other embodiments,
storage device is external to controller. For example, storage device may include
multiple storage units such as hard disks or solid state disks in a redundant array
of inexpensive disks (RAID) configuration. Storage device may include a storage area
network (SAN) and/or a network attached storage (NAS) system.
[0052] In some embodiments, processor is operatively coupled to storage device via a storage
interface. Storage interface is any component capable of providing processor with
access to storage device. Storage interface may include, for example, an Advanced
Technology Attachment (ATA) adapter, a Serial ATA (SATA) adapter, a Small Computer
System Interface (SCSI) adapter, a RAID controller, a SAN adapter, a network adapter,
and/or any component providing processor with access to storage device.
[0053] Memory area may include, but are not limited to, random access memory (RAM) such
as dynamic RAM (DRAM) or static RAM (SRAM), read-only memory (ROM), erasable programmable
read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM),
and non-volatile RAM (NVRAM). The above memory types are exemplary only, and are thus
not limiting as to the types of memory usable for storage of a computer program.
[0054] The excavation apparatus 3 may further include one or more user interfaces 160 (FIG.
12) to allow an operator to communicate with one or more components of the excavation
apparatus and the disentrainment controller 150. The user interface 160 may be supported
by a remote console 170 (shown in FIG. 12) and/or a stationary console 172 (FIG. 4).
The stationary console 172 may be integral to the excavation apparatus 3, i.e., the
console may be mounted to the chassis 14. The remote console 170 allows an operator
to remotely control the operation of the excavation apparatus 3. The remote console
170 may communicate with the disentrainment controller 150 by a communication link
that does not include a wire, such as a radio communication link. Additionally or
alternatively, the user interface 160 is communicatively coupled with the disentrainment
controller 150 such that an operator may override operations executed by the disentrainment
controller 150.
[0055] The user interface 160 may include any additional control devices used to control
or operate a function of the vehicle, for example and without limitation, the user
interface 160 may include buttons, knobs, and/or switches that may be used to start
or stop one or more of the excavation fluid pump 6, vacuum pump 24 and spray pump
102. The user interface 160 may further include a display screens and/or gauges used
to provide feedback to the operator. The user interface 160 may also include decals,
for example, images and/or instructions that may be interpreted by an operator.
[0056] After initiation of a separation operation in the excavation apparatus 3, spoil material
is drawn into the separation vessel 21 by the vacuum airstream where at least a portion
of the spoil material is separated from the airstream and discharged via the airlock
55. Any carryover spoil material is passed onto the cyclones 11 where additional spoils
are separated from the airstream and discharged from the system via the conveyors
80. As such, during a normal separation operation, at least some spoil material is
contained within the components of the disentrainment system 46 as spoil material
passes between each component. During a normal separation operation, the load cell
sensor 121 may measure an operating weight of the disentrainment system 46. This weight
may be compared to a tare weight that includes the empty weight of the weighed system
112 of the disentrainment system 46 (i.e., the tare weight subtracted from the operating
weight) to determine a spoil material weight. The tare weight corresponds to the empty
weight of the weighed system 112 (before operation or when a vacuum is applied to
the system without processing earthen slurry). The tare weight may be pre-set (e.g.,
factory set). In some embodiments, the tare weight may be recalibrated when desired
such as when the empty weight of the weighed system 112 is changed (e.g., service
work, replacing components, and/or by substitution of different vacuum hoses or the
like).
[0057] An operating weight is measured (by the sensor 121 which produces a signal that is
correlated to a weight or from which a weight is calculated) while excavating a site
with the excavation apparatus 3. A spoil material weight is calculated by subtracting
the tare weight from the operating weight. When the spoil material weight exceeds
one or more thresholds, the pluggage prevention system 60 may begin one or more mitigation
operations as described below.
[0058] As shown in FIG. 6, the disentrainment controller 150 includes a clearing module
200 for clearing a spoil build-up within the disentrainment system 46. The clearing
module 200 includes a set of instructions that may be executed by the disentrainment
controller 150. The clearing module 200 includes one or more weight thresholds or
"criterions" and one or more clearing operations. The disentrainment controller 150
may monitor a signal from the load cell sensor 121 in order to determine if a threshold
is satisfied. In response to one or more of the thresholds being satisfied, the disentrainment
controller 150 may execute one or more of the clearing operations.
[0059] The clearing module 200 includes determining a spoil material weight by subtracting
the tare weight from the operating weight of the weighed system 112 during a separation
operation. The disentrainment controller 150 receives a plurality of signals from
the load cell sensor 121 after initiation of excavation. In some embodiments, the
disentrainment controller 150 may average the operating weight of the weighed system
112 of the disentrainment system 46 over a period of time to determine the operating
weight.
[0060] The clearing module 200 includes a first clearing operation 208. The first clearing
operation 208 is activated when the first weight threshold is reached. The first weight
threshold (and second and third thresholds discussed below) may be selected based
on the size of the system, types of material being processed and ability of the system
to process surges of earthen material. Generally, the first, second and third weight
thresholds are pre-set (e.g., factory pre-set).
[0061] If the disentrainment controller 150 determines 206 that the first weight threshold
is satisfied, the disentrainment controller 150 executes the first clearing operation
208. In the first clearing operation 208, the disentrainment controller 150 transmits
a signal to the spray pump 102 such that pressurized water is provided to the first
spray nozzle assembly 104 and/or the second spray nozzle assembly 106. The first clearing
operation 208 may include supplying pressurized water to the spray nozzle assemblies
104, 106 at a cyclic pace such that the spray pump 102 is cycled between being powered
on for an amount of time and powered off for another amount of time. In this example
embodiment, the disentrainment controller 150 powers the spray pump 102 for two revolutions
or the airlock and then turns the spray pump 102 off for an amount of time, for example
and without limitation, 5 minutes. The disentrainment controller 150 may execute this
cycle for a plurality of times until the spoil build-up is cleared. More specifically,
the disentrainment controller 150 may continuously execute the first clearing operation
208 until the spoil material weight falls below the first threshold amount.
[0062] The clearing module further includes a second clearing operation 214 that is activated
when a second spoil material weight threshold is met (i.e., a weight threshold that
exceeds the first weight threshold). If the disentrainment controller 150 determines
that the second weight threshold is satisfied, the disentrainment controller 150 executes
a second clearing operation 214. The disentrainment controller 150 may execute the
second clearing operation 214 by transmitting a signal to the spray pump 102 such
that pressurized water is provided to at least one of the first spray nozzle assembly
104 and/or the second spray nozzle assembly 106. Additionally, the disentrainment
controller 150 may transmit a signal to the user interface 160, such that a warning
signal may indicate to the operator that a spoil build-up is occurring within the
disentrainment system 46. For example, the user interface 160 may illuminate a yellow
fault icon on a screen. In the second clearing operation 214 the controller may transmit
a signal to turn off the excavation fluid pump 6 to terminate expulsion of high-pressure
water from the wand 4 (FIG. 3). Additionally or alternatively, in the second clearing
operation 214 the controller 150 transmits a signal to turn off the vacuum pump 24.
During the second clearing operation 214, the operator may choose to override the
fault with remote console 170 or the on-board, stationary console 172 (FIG. 4) to
restart the excavation fluid pump 6 and/or the vacuum pump 24.
[0063] The clearing module also includes a third clearing operation 220. The third clearing
operation 220 is activated upon a third spoil weight threshold being met (i.e., a
spoil material weight that exceeds the first and second thresholds). The disentrainment
controller 150 executes the third clearing operation 220 by transmitting a signal
to the spray pump 102 such that pressurized water is provided to at least one of the
first spray nozzle assembly 104 and/or the second spray nozzle assembly 106. Additionally
or alternatively, the disentrainment controller 150 transmits a signal to the user
interface 160 such that a warning signal is displayed to be interpreted by an operator.
For example, a red fault icon is illuminated on the user interface 160.
[0064] In the third clearing operation 220, the disentrainment controller 150 initiates
a shutdown operation. For example, in the third clearing operation 220, the controller
transmits a signal to turn off the excavation fluid pump 6 and, optionally, the vacuum
pump 24 to terminate excavation. In some embodiments, during the third clearing operation
220, the operator may be limited to overriding the fault by interacting with the onboard
console 172 (FIG. 4) to restart the excavation fluid pump 6 and/or the vacuum pump
24, and functionality of the remote console 170 is limited. In some embodiments, if
the fault is over-ridden during the third clearing operation 220, the amount of time
the excavation fluid pump 6 and/or vacuum pump 24 may operate may be limited until
the weight of weighed system 112 drops below the third threshold.
[0065] An operator may wish to over-ride the shutdown operation, i.e., the operator may
wish to power the excavation fluid pump 6 and/or vacuum pump 24. In some embodiments,
the disentrainment controller 150 transmits a signal to the user interface 160 such
that an operator is prompted to acknowledge a warning signal prior to allowing the
operator to override the shutdown operation. More specifically, the operator may be
prompted to adjust at least one of a control device on the user interface 160 such
that a signal is transmitted to the disentrainment controller 150 indicating that
the operator is aware of the blockage. For example, after a shutdown operation the
vacuum pump 24 may be shut off. Prior to allowing an operator to turn back on the
vacuum pump 24, the operator may need to activate a button on the user interface 160
to acknowledge the spoil build-up.
[0066] The disentrainment controller 150 continuously monitors the weight of the weighed
system 112 of the disentrainment system 46 to calculate a spoil material weight within
the weighed system 112. Increases in the spoil material weight indicate that that
spoils are building up within one or more units of the disentrainment system 46. Further,
the magnitude of the spoil material weight indicates the severity of the spoil build-up,
i.e., the greater the spoil material weight, the greater the amount of spoils accumulating
within the disentrainment system 46. Further, the disentrainment controller 150 may
initiate a clearing operation based on the monitored weight. The clearing operation
may be tailored in response to the weight of the weighed system 112. In other words,
the greater the amount of spoils material within the disentrainment system 46, the
more aggressive the clearing operation performed to help mitigate a cascading blockage
of spoils.
[0067] It should be noted that the clearing module 200 shown in FIG. 6 is exemplary and
may include additional and/or different clearing condition thresholds and/or clearing
operations.
[0068] In some embodiments, the operator may input signals into the user interface 160 to
override an operation executed by the disentrainment controller 150 by adjusting one
or more control devices. For example, the operator may turn on and/or off one or more
of the spray nozzle assemblies 104, 106. For example, during the first clearing operation,
the disentrainment controller 150 transmits a signal to power the spray pump 102 to
supply water to at least one of the first spray nozzle assembly 104 and/or the second
spray nozzle assembly 106 for a clearing operation. The operator may override this
clearing operation by adjusting one or more user inputs on the remote console 170
and/or the stationary console 17 to control the operation of the spray pump 102.
[0069] In some example embodiments, the warning signals may include additional or alternative
signals that may be interpreted by an operator. For example, the warning signals may
include an auditory signal. In other example embodiments, a parameter of the separation
system may be displayed on the user interface 160. For example, a parameter associated
with the weight of the spoil material that has built-up in the disentrainment system
may be displayed for the operator.
[0070] It should be noted that, as an alternative to calculating a spoil material weight
based on the operating weight minus the tare weight, the tare weight may be built
into the various weight thresholds (i.e., the absolute weight of the system is compared
to a threshold that has the tare weight built into the threshold).
[0071] The disentrainment system 46 generally is meant to continuously process material
received in the system 46 without storing material such that the spoil material weight
represents material that has built up in the system and may result in pluggage rather
than material that is being stored in the system. The weighed system 112 does not
include processing units for storing the spoil material (e.g., a spoil tank).
[0072] As noted above, the excavation system may include various separation devices and
features of the example excavation system disclosed in
U.S. Patent Publication No. 2019/0017243, entitled "Hydro Excavation Vacuum Apparatus and Fluid Storage and Supply Systems
Thereof". For example, the separation vessel 21 includes an upper portion 51 (FIG.
7) having a sidewall 56 and one or more air outlets 49 formed in the sidewall 56.
The vessel 21 includes a lower portion 57 that tapers to the spoil material outlet
33 (FIG. 8). In the illustrated embodiment, the lower portion 57 is conical. The inlet
31 extends through the conical lower portion 57. In other embodiments, the inlet extends
through the upper portion 51.
[0073] In some embodiments, the disentrainment system 46 includes a single separation vessel
21 in the first stage removal of solids and water from the airstream. In other embodiments,
two or more separation vessels 21 are operated in parallel in the first stage removal
of solids and water from the airstream.
[0074] In the illustrated embodiment, the separation vessel 21 is a deceleration vessel
in which the velocity of the airstream is reduced causing material to fall from the
airstream toward a bottom of the separation vessel 21. The deceleration vessel 21
is adapted to allow material to fall from the airstream by gravity rather than by
vortexing of air within the vessel 21. In some embodiments, the inlet 31 of the vessel
21 is arranged such that the airstream does not enter the vessel 21 tangentially.
The deceleration system 23 also includes a deflection plate 27 (FIG. 8) disposed within
the deceleration vessel 21. The deflection plate 27 is configured and positioned to
cause spoil material entrained in the airstream to contact the plate 27 and be directed
downward toward the spoil material outlet 33.
[0075] From the spoil material outlet 33, the spoil material enters the airlock 55 (FIG.
9) and is discharged from the disentrainment system 46. The airlock 55 includes a
plurality of rotatable vanes 59 connected to a shaft 61. The vanes 59 rotate along
a conveyance path in the direction shown by arrow R in FIG. 9. The shaft 61 is connected
to a motor 58 (FIG. 7) that rotates the shaft 61 and vanes 59. The airlock 55 has
an airlock inlet 69 through which material passes from the deceleration vessel 21
and an airlock outlet 71 through which water and cut earthen material are discharged.
[0076] In other embodiments, a separation vessel 21 using cyclonic separation (i.e., a cyclone)
in which airflow travels in a helical pattern is used to remove material from the
airstream in a first state separation.
[0077] In embodiments in which material is excavated by pressurized water, after discharge
from the disentrainment system 46, the spoil material may be introduced into a dewatering
system 95 (FIG. 11). The dewatering system 95 of some embodiments includes a pre-screen
101 that first engages material discharged from the outlet 71 of the airlock 55. The
dewatering system 95 also includes a vibratory screen 109, more commonly referred
to as a "shaker", that separates material that passes through the pre-screen 101 by
size. The vibratory screen 109 may be part of a shaker assembly 113. The shaker assembly
113 includes vibratory motors 117 that cause the screen 109 to vibrate. As the screen
109 vibrates, effluent falls through openings within the screen 109 and particles
that do not fit through the openings vibrate to the discharge end of the assembly
113. Solids that reach the discharge end fall into a hopper 125 (FIG. 1) and may be
conveyed from the hopper 125 by a conveyor assembly 127 to form a stack of solids.
Solids may be loaded into a bin, dumpster, loader bucket, ground pile, roll-off bin,
dump truck or the like or may be conveyed to the site of the excavation as backfill.
Solids may be transported off of the excavation apparatus by other methods. The dewatering
system 95 of the present disclosure may include additional separation and/or purification
steps for processing cut earthen material.
[0078] In may be noted that in some cases, a small portion of spoils may become trapped
or caught in various locations within the components of the separation system 67,
for example and without limitation, corners, edges, and the like, without significantly
impeding a separation operation and/or clogging or plugging the components of the
disentrainment system 46. In other words, a minimal amount of spoils may build-up
within the spoil separation system 67 without significantly affecting the systems
and methods disclosed herein. For example, in some cases, at least some material may
build up on the one or more filter elements.
[0079] The hydro excavation vacuum apparatus 3 may include a fluid storage and supply system
25 which supplies water for high pressure excavation and stores water recovered from
the dewatering system 95. The fluid storage and supply system 25 includes a plurality
of vessels 30 for holding fluid.
[0080] Compared to conventional excavation apparatus, the apparatus of the present disclosure
has several advantages. By monitoring the weight of the spoil material that builds-up
in the disentrainment system of the apparatus, the system may be monitored to prevent
pluggage. Build-up of spoil material may be mitigated by adding water to the system
to help process material through the disentrainment system. The pluggage prevention
system may disable excavation to prevent further spoil materials from building up
in the system. In this manner, pluggage of the system may be avoided which increases
the run-time of the apparatus. The pluggage prevention system may warn the operator
that the system is nearing a pluggage condition to allow the operator to change operation
of the system.
[0081] As used herein, the terms "about," "substantially," "essentially" and "approximately"
when used in conjunction with ranges of dimensions, concentrations, temperatures or
other physical or chemical properties or characteristics is meant to cover variations
that may exist in the upper and/or lower limits of the ranges of the properties or
characteristics, including, for example, variations resulting from rounding, measurement
methodology or other statistical variation.
[0082] When introducing elements of the present disclosure or the embodiment(s) thereof,
the articles "a", "an", "the" and "said" are intended to mean that there are one or
more of the elements. The terms "comprising," "including," "containing" and "having"
are intended to be inclusive and mean that there may be additional elements other
than the listed elements. The use of terms indicating a particular orientation (e.g.,
"top", "bottom", "side", etc.) is for convenience of description and does not require
any particular orientation of the item described.
[0083] As various changes could be made in the above constructions and methods without departing
from the scope of the disclosure, it is intended that all matter contained in the
above description and shown in the accompanying drawing[s] shall be interpreted as
illustrative and not in a limiting sense.